High density chip packages, methods of forming, and systems including same

ABSTRACT

Methods and devices for multi-chip stacks are shown. A method is shown that assembles multiple chips into stacks by stacking wafers prior to dicing into individual chips. Methods shown provide removal of defective chips and their replacement during the assembly process to improve manufacturing yield.

RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.11/583,411, filed Oct. 19, 2006, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

This application relates generally to semiconductor devices and devicefabrication and, more particularly, to embodiments of multi-chippackages.

BACKGROUND

An ever present goal in the semiconductor industry has been to decreasethe size of devices and to increase the performance of devices. However,both of these goals present large technical hurdles as the two goals areoften in conflict with each other.

As the minimum feature size achievable in semiconductor manufacturingdecreases, the capacitive coupling between adjacent metal lines becomesa significant impediment to achieving higher performance. Further, asthe minimum feature size decreases, the number of devices potentiallyachievable in a given area increases, as a second power function. Thenumber of wiring connections is increasing at least as rapidly. In orderto accommodate the increased wiring, the chip designer would like toshrink the space between adjacent lines to the minimum achievabledimension. This has the unfortunate effect of increasing the capacitiveload.

One way to accommodate the increased wiring and reduce capacitive loadis to substitute lower dielectric constant materials for the insulatingmaterial. A common insulating material to date is SiO₂, which has adielectric constant of around 4. SiO₂ is now used in most very largescale integrated circuit (VLSI) chips. Another way to accommodate theincreased wiring and reduce capacitive load is to shorten the distancebetween devices by denser packaging.

Multi-chip stacking has been proposed in the past; however, onesignificant concern with stacking chips (i.e. memory chips, logic chips,processor chips, etc.) is the manufacturing yield of the assembly.Because any given wafer will currently have a percentage of defectivechips on its surface, when multiple wafers are stacked, for example 10wafers high, the likelihood of at least one defective chip in any givenstack goes up significantly. Alternatively, stacking individual chipsthat have been tested and known to be good involves a greater amount ofhigh precision handling when compared to stacking wafers prior todicing. In either scenario, a high amount of loss due to manufacturingyield is present.

What are needed are methods and devices that improve the manufacturingyield of large numbers of stacked chips in a multi-chip assembly. Whatare also needed are improved methods and devices to enhance performance,reduce size, and improve other properties and features of multi-chipassemblies.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an electronic system according to an embodiment of theinvention.

FIG. 2A-2C show two wafers in various stages of chip assembly accordingto an embodiment of the invention.

FIG. 3A-3C show cross section views of wafers in various stages of chipassembly according to an embodiment of the invention.

FIG. 4 shows a multi-chip assembly according to an embodiment of theinvention.

FIG. 5 shows another multi-chip assembly according to an embodiment ofthe invention.

DETAILED DESCRIPTION

In the following detailed description of the invention, reference ismade to the accompanying drawings that form a part hereof and in whichis shown, by way of illustration, specific embodiments in which theinvention may be practiced. In the drawings, like numerals describesubstantially similar components throughout the several views. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the invention. Other embodiments may be utilizedand structural, logical, and electrical changes may be made withoutdeparting from the scope of the present invention.

The terms “wafer” and “substrate” used in the following descriptioninclude any structure having an exposed surface with which to form anintegrated circuit (IC) structure of the invention. The term substrateis understood to include semiconductor wafers. The term substrate isalso used to refer to semiconductor structures during processing and mayinclude other layers, such as silicon-on-insulator (SOI), etc. that havebeen fabricated thereupon. Both wafer and substrate include doped andundoped semiconductors, epitaxial semiconductor layers supported by abase semiconductor or insulator, as well as other semiconductorstructures well known to one skilled in the art. The term conductor isunderstood to include semiconductors and the term insulator ordielectric is defined to include any material that is less electricallyconductive than the materials referred to as conductors.

The term “horizontal” as used in this application is defined as a planeparallel to the conventional plane or surface of a wafer or substrate,regardless of the orientation of the wafer or substrate. The term“vertical” refers to a direction perpendicular to the horizontal asdefined above. Prepositions, such as “on,” “side” (as in “sidewall”),“higher,” “lower,” “over,” and “under” are defined with respect to theconventional plane or surface being on the top surface of the wafer orsubstrate, regardless of the orientation of the wafer or substrate.

Although the terms “memory chip” and “logic chip” are used in thefollowing description, one of ordinary skill in the art will recognizethat in one embodiment, a chip may include both memory circuitry andlogic circuitry on the same chip. A chip with both memory circuitry andlogic circuitry on the same chip is defined to be both a “memory chip”and a “logic chip” as used in the following description. The followingdetailed description is, therefore, not to be taken in a limiting senseand the scope of the present invention is defined only by the appendedclaims, along with the full scope of equivalents to which such claimsare entitled.

An embodiment of an information handling system such as a personalcomputer is included to show an embodiment of a high-level deviceapplication for the present invention. FIG. 1 is a block diagram of aninformation handling system 1 incorporating at least one multi-chipassembly 4 formed by methods in accordance with one embodiment of theinvention. Information handling system 1 is merely one embodiment of anelectronic system in which the present invention can be used. Otherexamples include, but are not limited to, personal data assistants(PDAs), cellular telephones, MP3 players, aircraft, satellites, militaryvehicles, etc.

In this example, information handling system 1 comprises a dataprocessing system that includes a system bus 2 to couple the variouscomponents of the system. System bus 2 provides communications linksamong the various components of the information handling system 1 andmay be implemented as a single bus, as a combination of busses, or inany other suitable manner.

Multi-chip assembly 4 is coupled to the system bus 2. Multi-chipassembly 4 may include any circuit or operably compatible combination ofcircuits. In one embodiment, multi-chip assembly 4 includes a processor6 that can be of any type. As used herein, “processor” means any type ofcomputational circuit such as, but not limited to, a microprocessor, amicrocontroller, a graphics processor, a digital signal processor (DSP),or any other type of processor or processing circuit.

In one embodiment, a memory chip 7 is included in the multi-chipassembly 4. Those skilled in the art will recognize that a wide varietyof memory chips may be used in the multi-chip assembly 4. Acceptabletypes of memory chips include, but are not limited to, Dynamic RandomAccess Memory (DRAMs) such as SDRAMs, SLDRAMs, RDRAMs and other DRAMs.Memory chip 7 can also include non-volatile memory such as flash memory.

In one embodiment, additional logic chips 8 other than processor chipsare included in the multi-chip assembly 4. An example of a logic chip 8other than a processor includes an analog to digital converter. Othercircuits on logic chips 8 such as custom circuits, anapplication-specific integrated circuit (ASIC), etc. are also includedin one embodiment of the invention.

Information handling system 1 may also include an external memory 11,which in turn can include one or more memory elements suitable to theparticular application, such as one or more hard drives 12, and/or oneor more drives that handle removable media 13 such as floppy diskettes,compact disks (CDs), digital video disks (DVDs), and the like.

Information handling system 1 may also include a display device 9 suchas a monitor, additional peripheral components 10, such as speakers,etc. and a keyboard and/or controller 14, which can include a mouse,trackball, game controller, voice-recognition device, or any otherdevice that permits a system user to input information into and receiveinformation from the information handling system 1.

FIGS. 2A-2C show selected acts in a process of forming multi-chippackages according to an embodiment of the invention. In FIG. 2A, afirst wafer 210 and a second wafer 220 are shown. The first wafer 210includes a number of individual chips 212 and the second wafer includesa number of individual chips 222.

In FIG. 2B, the second wafer 220 is electrically coupled to the firstwafer 210 to form a wafer assembly 200. In the operation, each of themultiple individual chips 212 are aligned and coupled with multipleindividual chips 222. In wafer form, the joining process between chips212 and 222 is easier and produces a higher manufacturing yield. Amongother factors, the larger size makes handling and connection easierbetween chips on the first wafer 210 and the second wafer 220. Also theinterconnection process joins multiple chips 212, 222 in a singleoperation.

In FIG. 2B, the second wafer 220 is shown having a thickness 224. In onemethod of manufacture, the individual chips 222 are partially scored inthe wafer 220 prior to attachment to the first wafer 210. In one methodthe scored side of the second wafer 220 is located at the interfacebetween the first wafer 210 and the second wafer 220 after joining asshown in FIG. 2B.

FIG. 2C shows a stage in one method of manufacture where the secondwafer 220 is thinned from thickness 224 as shown in FIG. 2B to athickness 226 as shown in FIG. 2C. In one method of manufacture, thepartial scoring of the second wafer 220 is completed by the thinningprocess in FIG. 2C to allow separation of individual chips 222. Althoughpartial scoring and thinning are discussed as one method to separateindividual chips 222 from the second wafer 220, the invention is not solimited. One of ordinary skill in the art, having the benefit of thepresent disclosure, will recognize that other methods of separatingindividual chips 222 such as full thickness sawing after waferconnection, etc. are encompassed by the present invention.

In one embodiment, the second wafer 220 is positioned with individualchips 222 in flip-chip orientation to connect to the individual chips212 on the first wafer 210. In one embodiment, the first wafer includessubstantially all high-yield circuits to increase the likelihood thatall or most of the individual chips 212 on the first wafer 210 are freeof defects. An example of a high-yield circuit in one embodimentincludes only re-distribution plane circuitry on the individual chips212.

In one embodiment the second wafer includes memory chips such as dynamicrandom access memory, although the invention is not so limited. Onemethod includes testing all individual chips 222 prior to connecting thesecond wafer 220 to the first wafer 210. Defective chips are identifiedduring the testing process. As shown in FIG. 2C, after individual chips222 are coupled to the first wafer 210 and separated, defective chipscan be removed from the wafer assembly 200 without disturbing the otherchips 222 that remain connected to the first wafer 210. The removal ofdefective chips leaves gaps in the chips 222 such as first gap 234 andsecond gap 236. Good chips 230 and 232 can then be inserted into gap 234and gap 236 to form a complete array of chips 222 without any defectivechips present. Where chips 222 were thinned prior to defective chipremoval, a number of previously thinned good chips are used to fill gapssuch as 234 and 236.

The process described above and in FIGS. 2A-2C may be repeated to formmulti-wafer stacks. Because defective chips are being removed andreplaced as the stack progresses, a final wafer stack includes multiplechip stacks without any defective chips. The assembly process ofstacking chips is made easier by stacking wafers, yet the manufacturingyield of a given wafer stack is significantly increased by replacingindividual defective chips with good chips along the way during eachadditional wafer level assembly.

In one embodiment, a holding wafer is attached to the stack of wafersafter the last functional wafer is added in the stack. The first wafer,such as the redistribution circuit wafer, can then be diced or separatedby thinning, etc. Later, the holding wafer can be removed or diced, etc.to safely separate the individual multi-chip stacks. In one embodiment,the holding wafer attachment is temporary and the individual multi-chipstacks are later removed from the holding wafer. In one embodiment, thelast wafer in the stack prior to the holding wafer is scored deeper thanthe prior wafers to provide for easier separation with less chipthinning.

Many different stacks of chips are contemplated, in accordance withembodiments of the invention, using the techniques described above. Onecontemplated embodiment of a chip stack includes a high-yieldredistribution circuit chip on the bottom, with multiple memory chipsstacked on top, with a logic chip such as a processor chip stacked ontop. In one embodiment, a logic chip in the stack includes both logiccircuitry and static random access memory. Other contemplatedconfigurations include the logic chip located adjacent to theredistribution circuit chip. Specific reasons for such a configuration,such as multiple processor embodiments, are discussed below. Although achip stack including a redistribution circuit chip, at least one memorychip, and a logic chip are described herein, the invention is not solimited. Techniques described above are useful for manufacturing anystack of more than one chip.

FIGS. 3A-3C show side views of a chip manufacturing operation accordingto embodiments of the invention. A first chip 310 is shown oriented inflip-chip orientation in FIG. 3A. The first chip 310 includes a numberof devices 332 such as transistors, memory cells, etc. The devices 332are shown formed in a substrate 330 with a thickness 316. Horizontalredistribution circuitry 340, such as metal trace lines, and vias orcontacts 338 are shown interconnecting devices 332 within the first chip310. One or more regions of insulator 334, such as silicon dioxide, maybe used to electrically isolate the redistribution circuitry 340.

In one embodiment, the first chip 310 includes a first verticalcommunication channel 344 and a second vertical communication channel346. The first vertical communication channel 344 includes a via, or thelike. Several types of communication channel 344 are within the scope ofthe invention, including metal conductors, optical conductors, etc. Thesecond vertical communication channel 346 illustrates a coaxialconductor embodiment. As shown in FIG. 3A, prior to connection toanother wafer, the vertical communication channels do not pass throughan entire thickness of the first chip 310.

FIG. 3B shows the first chip 310 coupled in flip-chip orientation to asecond chip 320 using connection structures 312. In one embodiment, thesecond chip 320 includes a high-yield chip such as a redistributioncircuit chip and the first chip 310 includes a memory chip. However, thedescription in FIGS. 3A-3C is applicable to a connecting operationbetween any two chips in a chip stack.

In one embodiment, the connection structures 312 include solderstructures such as controlled chip collapse connections (C4). Any of anumber of pad metallurgies are possible to support the connectionstructures 312. One pad metallurgy includes TiNiCuAu pads. In oneembodiment TiNiCuAu pads are formed using a liftoff process. Oneadvantage of TiNiCuAu pads formed using a liftoff process includes theability to form smaller contacts, thus permitting a more denseinterconnection configuration. Although solder connection structures 312are described, the invention is not so limited. Other possibleconnection structures 312 include gold to gold bonding connectionstructures, conductive epoxies, conductor filled epoxies, conductivefilms, etc.

FIG. 3B shows an embodiment where the connection structures 312 leave agap 314 between the first chip 310 and the second chip 320. In oneembodiment the gap 314 is filled with a solid material. In otherembodiments the gap 314 is left open. Filled embodiments may useadhesives such as epoxy or other filler material to provide additionalmechanical strength to a final multi-chip assembly.

In embodiments where the gap 314 is left open, a cooling fluid such as agas or liquid is able to pass between individual chips in a chip stackto enhance cooling during operation. In one electronic systemembodiment, a cooling system utilizing the gaps 314 is coupled to thesystem to cool a chip stack formed according to methods described. Inone embodiment, the cooling system uses a gas or a compressed gas toflow through the gaps 314 and cool the individual chips. One compressedgas includes compressed hydrogen. One compressed gas includes compressedhelium. In selected embodiments, a composite gas of hydrogen and heliumis used for cooling. Liquid cooling fluids contemplated forimplementation of embodiments of the invention include volatile liquidsand supercritical fluids such as liquid carbon dioxide.

FIG. 3C shows the first chip 310 that has been thinned from thickness316 as shown in FIG. 3B to thickness 318. In addition to completing ascoreline for chip separation as described above, thinning chips in awafer may be used to expose circuitry for additional chipinterconnectivity from the back side of the wafer. FIG. 3C shows thefirst vertical communication channel 344 and the second verticalcommunication channel 346 as described above. In one embodiment, thethinning process exposes vertical communication channels in the form ofthrough-wafer interconnects to permit through chip interconnectivity.

One advantage of through chip interconnectivity as opposed to chip edgeinterconnectivity includes the increased density of interconnectivitythat is possible. Chip edge connections between chips in a multi-chipstack are limited by the amount of chip edge real estate. In contrast,through chip connections can pass through any available location withinthe plane of each chip. In one embodiment, both chip edge connectionsand through chip connections are used to communicate between chips in amulti-chip stack. Although through chip interconnections are described,embodiments using only chip edge connections are also within the scopeof the invention.

FIG. 4 shows one embodiment of a chip stack 400 formed using methodsdescribed above. In one embodiment, a bottom chip 410 includes ahigh-yield chip such as a redistribution circuitry chip. A number ofmemory chips 420 are shown located on top of the redistributioncircuitry chip 410. A logic chip 430 such as a processor chip is stackedon top of the chip stack 400. In one embodiment, nine memory chips 420are stacked on top of the bottom chip 410 with a single logic chip 430stacked on top of the memory chips 420. Other embodiments includemultiple redistribution circuitry chips in a single stack 400, multiplelogic chips 430 in a single stack 400, and any of a number of differentstacking orders for the stack 400. Placing a redistribution circuitrychip first provides a high-yield base wafer that increases manufacturingyield as described above. Placing at least one logic chip 430 on anoutside surface of the stack 400 allows for increased cooling of one ofthe hotter running chips in the stack.

FIG. 5 shows a chip stack 500 including multiple logic chips such asmultiple processors. Two or more redistribution circuitry chips 512 areagain used as a base, with two or more logic chips 510 mounted on top ofthe redistribution circuitry chips 512. A number of memory chips 520 arethen stacked on top of the two or more logic chips 510.

While a number of advantages of embodiments of the invention aredescribed, the above lists are not intended to be exhaustive. Althoughspecific embodiments have been illustrated and described herein, it willbe appreciated by those of ordinary skill in the art that anyarrangement that is calculated to achieve the same purpose may besubstituted for the specific embodiment shown. This application isintended to cover any adaptations or variations of the presentinvention. It is to be understood that the above description is intendedto be illustrative and not restrictive. Combinations of the aboveembodiments, and other embodiments, will be apparent to those of skillin the art upon reviewing the above description. The scope of theinvention includes any other applications in which the above structuresand methods are used. The scope of the invention should be determinedwith reference to the appended claims, along with the full scope ofequivalents to which such claims are entitled.

1. A semiconductor wafer assembly, comprising: a first wafer layer,including a number of chip sized regions in an array; and a second waferlayer attached to the first wafer layer, including a number ofsemiconductor chips in an array substantially matching the array of chipsized regions, wherein selected semiconductor chips from the number ofsemiconductor chips have been removed from the surface of the firstwafer layer.
 2. The semiconductor wafer assembly of claim 1, wherein thenumber of chip sized regions includes only redistribution circuitry. 3.The semiconductor wafer assembly of claim 1, wherein the number of chipsized regions includes memory chips.
 4. The semiconductor wafer assemblyof claim 1, wherein the number of semiconductor chips includes logicchips.
 5. The semiconductor wafer assembly of claim 1, wherein thenumber of semiconductor chips includes memory chips.
 6. A semiconductorwafer assembly, comprising: a first wafer, including only redistributioncircuitry; and a second wafer attached to the first wafer, including anumber of flash memory chips, wherein selected chips from the number offlash memory chips have been removed from the surface of the firstwafer.
 7. The semiconductor wafer assembly of claim 6, wherein the chipsin the second wafer are attached to the first wafer using controlledchip collapse connections (C4).
 8. The semiconductor wafer assembly ofclaim 6, wherein the chips in the second wafer are attached to the firstwafer using TiNiCuAu pad metallurgy.
 9. A multi-chip stack, comprising:an end chip that includes only redistribution circuitry; a plurality ofchips stacked on the end chip, including: at least one memory chip; andat least one logic chip.
 10. The multi-chip stack of claim 9, whereinthe at least one memory chip includes a dynamic random access memory(DRAM) chip.
 11. The multi-chip stack of claim 9, wherein the at leastone memory chip includes a flash memory chip.
 12. The multi-chip stackof claim 9, wherein a second end chip, opposite the end chip thatincludes only redistribution circuitry is thicker than other chips inthe plurality of chips.
 13. The multi-chip stack of claim 9, wherein theplurality of chips are interconnected using both chip edge connectionsand through chip connections.
 14. An electronic system, comprising: amulti-chip stack, including: an end chip that includes onlyredistribution circuitry; a plurality of chips stacked on the end chip,including: at least one memory chip; and at least one logic chip acooling system, coupled to the multi-chip stack to flow a cooling fluidthrough at least one gap at an interface between at least two chips inthe plurality of chips.
 15. The electronic system of claim 14, whereinthe fluid includes a liquid.
 16. The electronic system of claim 14,wherein the fluid includes a supercritical fluid.
 17. The electronicsystem of claim 16, wherein the supercritical fluid includes carbondioxide.
 18. The electronic system of claim 14, wherein the fluidincludes a pressurized gas.
 19. The electronic system of claim 18,wherein the pressurized gas includes hydrogen.
 20. The electronic systemof claim 18, wherein the pressurized gas includes helium.
 21. Theelectronic system of claim 18, wherein the pressurized gas includes bothhydrogen and helium.